The purpose of this thesis was to analyze and understand the functions of the current temperature model used at the steel mill in at SSAB in Oxelösund. Furthermore, to try to optimize the model by creating a better description of the ladles thermal status. A copy of the current model was made using Matlab and its performance was compared to actual temperature measurements. Along with this, additional process data was used to find a correlation between these data and temperature alterations in the liquid steel. These correlations were then used to create a new description of the ladles thermal status in a modified temperature model. The results show that the thermal status of the ladle has a big influence on the steel temperature throughout the steel making process. Also, the thermal status is greatly affected by the how the ladles are handled when being empty. The results also show that a model using a unique thermal status calculated for each heat, based on correlations derived from stored process data, provides a better result than the current model which is based on pre-determined heat loss curves. / Syftet med det här projektet var att kartlägga och förstå funktionerna i den befintliga temperaturmodellen som används i stålverket i Oxelösund samt att försöka optimera modellen genom att på ett bättre sätt beskriva skänkens värmestatus. En kopia av den nuvarade modellen gjordes med hjälp av Matlab och jämfördes med verkliga temperaturmätningar. Sedan användes ytterliggare processdata för att hitta samband mellan dessa och temperaturförändringar i stålet. Dessa samband änvändes sedan för att skapa en ny beskrivning av skänkens värmestatus i en modiferad temperaturmodell. Projektets resultat visar på att skänkens värmestatus har en väldigt stor påverkan på temperatur-förändringar i stålet och att det som påverkar värmestatusen mest är hur skänken hanteras när den är tom. Resultaten visar också att en modell med en unik värmestatus för varje skänk uträknad med samband härledda från processparameterar ger ett bättre resultat än   resultaten   från   dagens   modell   där   förbestämda   värmeförlustkurvor  bestämmer skänkens värmestatus.

The present dissertation describes part of the efforts directed towards the development of computational tools to support process modeling. This work is also a further development of the Thermoslag software developed in the Division of Materials Process Science, KTH. The essential parts of the thesis are a) development of a semi-empirical model for the estimation of the molar volumes/densities of multicomponent slags with a view to incorporate the same in the model for viscosities and b) further development of the viscosity model for application towards fluorid- containing slags, as for example, mould flux slags. The model for the estimation of molar volume is based on a correlation between the relative integral molar volume of a slag system and the relative integral molar enthalpies of mixing of the same system. The integral molar enthalpies of the relevant systems could be evaluated from the Gibbs energy data available in the Thermoslag software. The binary parameters were evaluated from experimental measurements of the molar volumes. Satisfactory correlations were obtained in the case of the binary silicate and aluminate systems. The model was extended to ternary and multi component systems by computing the molar volumes using the binary parameters. The model predictions showed agreements with the molar volume data available in literature. The model was used to estimate the molar volumes of industrial slags as well as to trace the trends in molar volume due to compositional variations. The advantage of the present approach is that it would enable prediction of molar volumes of slags that are compatible with the thermodynamic data available. With a view to extend the existing model for viscosities to F--containing slags, the viscosities of mould flux slags for continues casting in steel production have been investigated in the present work. The measurements were carried out utilizing the rotating cylinder method. Seven mould fluxes used in the Swedish steel industry and the impact of Al2O3 pick up by mould flux slags on viscosities were included in the study. The results showed that even relatively small additions of Al2O3 are related with a significant increase in viscosity / QC 20101123

Bifilms is the oxide layer created between two surfaces in the melt of light metals that form an oxide layer. These become planar inclusions in the final casting and are problematic for the mechanical properties such as cracks and crack initiations. Bifilms are too thin to be viewed properly in two dimension cross-section method as they will only appear as thin lines. Because of this, it is relevant to test if it is possible to use electrolytic extraction (EE) as a alternative method to investigate bifilms. Both the deeply etched surface and the inclusions on a filter from the extraction are looked at in the scanning electron microscope (SEM) to get an understanding of the size and shape of the inclusions. With this, a greater understanding of these types of defects can be achieved. After both the filtered inclusions and the surface are examined in SEM with images and Energy-dispersive X-ray spectroscopy (EDS), the images are measured in the software ImageJ. The measurements and analysis show that it is probably bifilms and that they can be relatively large, and not so circular. However, the measurements with the filter have shown high levels of oxygen and carbon. Some levels of chlorine, nitrogen and iron have also been found. But if the surface is compared to the metal surface, it can be concluded that it is likely that bifilms have been found. There are sufficient levels of aluminum and oxygen present. Images in SEM also show the appearance of film-like inclusions. If the method of electrolytic extraction is to be improved to investigate bifilms,optimizations such as filters of other compositions are recommended. / Bifilms är det oxidskikt som skapas mellan två ytor i smältan hos lätta metaller som bildar ett oxidskikt. Dessa blir sedan plana inneslutningar i den slutliga gjutningen och är problematiskt för de mekaniska egenskaperna i form av sprickor och sprickinitieringar. Bifilms är för tunna för att de ska kunna ses korrekt i en tvärsnittsmetod, eftersom de bara kommer att visas som tunna linjer. På grund av detta är det relevant att testa om det är möjligt att använda elektrolytisk extraktion (EE) som en alternativ metod. Både den djupt etsade ytan och inneslutningarna på ett filter från extraktionen tittas på i svepelektronmikroskop för att få en förståelse för inneslutningarnas storlek och form. I och med det kan en högre förståelse uppnås för dessa typer av defekter. Efter att både de filtrerade inneslutningarna och ytan granskats i SEM med bilder och Energy-dispersive X-ray spectroscopy (EDS), mäts bilderna i en mjukvara, ImageJ. De mätningarna och analyserna visar att det antagligen hittats bifilms och att de kan vara förhållandevis stora, samt inte så cirkulära. Däremot har mätningarna med filtret visat höga halter av syre och kol. Även vissa halter av klor, kväve och järn har hittats. Men om ytan jämförs med metallytan så kan en slutsats dras om att det är troligt att bifilms har hittats. Där finns tillräckliga halter av aluminium och syre. Även bilder i SEM påvisar filmliknande inneslutningar till sitt utseende. Om metoden med elektrolytisk extraktion ska förbättras för att undersöka bifilms behövs optimeringar, som till exempel filterav en annan sammansättning.

When producing high strength special steels strict requirements are in place to assure the quality of the final product, both in terms of harmful elements and  the  content  of  non-metallic  inclusions  (NMI).  Achieving  cleanliness  is a  gradual  process  where all  the  steps  of  the  production  process  are  inter- connected, meaning that it is crucial to know the influence of each step in order to assure the contents of the final product.  The purpose of this thesis was to investigate the presence of non-metallic inclusions in wear plate steel, produced through two different process routes, one with an added round of Ca treatment and vacuum treatment. The  investigations  were  performed  using  electrolytic  extraction  of  in- clusions  followed  by  analysis  with  a  scanning  electron  microscope  (SEM). Backscattered electrons (BSE) were used for imaging and morphology anal- ysis and composition analysis was performed using energy dispersive spec- troscopy (EDS). Four different types of inclusions were found in the samples, whereof only one type is present in liquid steel.  It was found that the ini- tial Ca treatment stabilised the composition for the vacuum treated samples, while the sizes of the inclusions found in these samples were scattered.  The reverse was observed in the reference samples, where compositions were scat- tered but a mode value could be found for inclusion size at around 2.5 µm. Inclusions in the reference samples were found to have an average composi- tion lying outside the desired liquid region, not achieving full modification of harmful inclusions, while only modified inclusions could be found in vacuum treated samples. Additionally, around 70% of the analysed inclusions in the vacuum treated samples could be found in the liquid region. It was also found that the use of an electrolytic extraction method was appropriate for the investigated steel grade, while highlighting the need for some parameter adjustments to be made for future investigations in order to extract a sufficient number of inclusions. / Vid tillverkning av höghållfasta specialstål ställs stränga krav för att säkerställa kvaliteten på slutprodukten, både vad gäller skadliga element och innehållet av  icke-metalliska  inneslutningar  (NMI).  Att  uppnå  renlighet  är  en  gradvis  process  där alla  steg  i  produktionsprocessen  är  sammankopplade,  vilket innebär  att  det  är avgörande  att  känna  till  varje  stegs  inverkan  för  att säkerställa innehållet i slutprodukten.  Syftet med detta examensarbete var att  undersöka  förekomsten  av icke-metalliska  inneslutningar  i  slitplåtsstål, producerade genom två olika processvägar, en med en extra omgång av Ca- behandling och vakuumbehandling. Undersökningarna  utfördes  med  hjälp  av  elektrolytisk  extraktion  av  inneslutningar  följt  av  analys  med  ett  svepelektronmikroskop  (SEM).  Tillbakaspridda  elektroner  (BSE)  användes  för  avbildning  och  morfologianalys och sammansättningsanalys utfördes med användning av energidispergerande spektroskopi (EDS). Fyra olika typer av inneslutningar hittades i proverna, varav  endast  en  typ  förekommer  i  flytande stål.    Det  visade  sig  att  den initiala  Ca-behandlingen  stabiliserade sammansättningen  för  de  vakuumbehandlade proverna, medan storleken på inneslutningarna som hittades i dessa prover var spridda.  Det omvända observerades i referensproverna, där sammansättningarna  var  spridda  men  ett  modvärde  kunde hittas  för  inneslutningsstorleken  på  cirka  2,5  µm. Inneslutningar  i referensproverna visade sig  ha  en  genomsnittlig  sammansättning  som  låg  utanför  den  önskade flytande  regionen,  där  fullständig  modifiering  av  skadliga inneslutningar  inte uppnåtts, medan endast modifierade inneslutningar kunde hittas i vakuumbehandlade prover.  Dessutom kunde cirka 70% av de analyserade inneslutningarna i de vakuumbehandlade proverna hittas i den flytande regionen. Det visade sig också att användningen av en elektrolytisk extraktionsmetod var lämplig för den undersökta stålsorten, samtidigt som behovet av att göra vissa parameterjusteringar inför framtida undersökningar framhölls, för att kunna extrahera en tillräcklig mängd inneslutningar.

Inclusions in molten steel have received worldwide concern due to their serious influence on both the steel product quality and the steel production process. These inclusions may come from the deoxidation process, reoxidation by air and/or slag due to an entrainment during steel transfer, and so on. They can break up a casting process by clogging a nozzle. A good knowledge on both steel flow and inclusion behavior is really important to understand nozzle clogging, as well as to take some possible measures to alleviate clogging. In this thesis, steel flow and inclusion behavior during a teeming process were investigated by mathematical simulations with verification by pilot-plant experiments. Firstly, steel flow phenomena during a ladle teeming process were studied. Different turbulence models, including the low Reynolds number k-ɛ model and the realizable k-ɛ model both with an enhanced wall treatment (EWT) and a standard wall function (SWF), were used to simulate this process. All of these turbulence model predictions generally agreed well with the experimental results. The velocity distributions in the nozzle were also predicted by these turbulence models. A large difference of the boundary-layer velocity predicted with these two near wall treatment methods was found. At the late stage of the teeming process, the drain sink flow phenomena were studied. The combination of an inclined ladle bottom and a gradually expanding nozzle was found to be an effective way to alleviate a drain sink flow during teeming. Then, inclusion behavior during a teeming stage was studied. A Lagranian method was used to track the inclusions in steel flow and compare the behaviors of different-size inclusions. In addition, a statistical analysis was conducted by the use of a stochastic turbulence model to investigate the behaviors of different-size inclusions in different nozzle regions. Inclusions with a diameter smaller than 20μm were found to have a similar trajectory and velocity distribution in the nozzle. However, inertia force and buoyancy force were found to play an important role for the behavior of large-size inclusions or clusters. The statistical analysis results indicate that the regions close to the connection between different angled nozzle parts seem to be very sensitive for an inclusion deposition. / <p>QC 20130305</p>

This thesis is meant to serve as part of a competence platform for future product development projects at Sandvik Coromant AB, Solid Round Tools Department, Västberga, Sweden. The project objective is to gain generic knowledge of the wear mechanisms that restrict tool lifetime when drilling austenitic stainless steel. Thus, identifying if the weakest link of the tool is located within the coating, the coating adherence or in the strength of the substrate. A theoretical review of the work-piece and tool materials has been conducted as a background, along with definition of tool geometry and process parameters. Furthermore, the review includes chemical and process design effect on mechanical properties of the austenitic stainless steel, TiAlN coatings and cemented carbide substrates. Additionally, the basic principles of the wear mechanisms and wear types that are specific to drilling have been reviewed. During the experimental procedures both solid and exchangeable tip drills from cemented carbide with multilayered PVD TiAlN coatings were tested. Two series of tests were conducted, the first series aimed to identify wear type dependency on cutting speed, focusing on wear of the tool margin. The second test series was performed to map the wear progression depending on distance. Analyses including identification the main wear mechanism, quantification the amount of wear, identify wear location on the tool, crack investigation and WDS analysis of chemical wear. Adhesive coating wear was found on the tool margin at an early stage. The adhesive wear rapidly progressed into a stable intermediate stage. Leaving the substrate exposed and more susceptible to other wear types resulting in crack and oxide layer formation.

Spinodal decomposition is a phenomenon which hinders the usage of ferrite containing steels under certain conditions. With a better understanding and knowledge of spinodal decomposition new ferritic and duplex stainless steels could be designed. The project is divided into two parts, an experimental part and a theoretical part. The aim of the theoretical part was to compare simulated values of the amplitude and wavelength of spinodal decomposition, obtained from solving the Cahn-Hilliard equation with other experimental values. The experimental part is performed as to determine the chemical diffusion coefficient and the mobility of Fe and Cr in the binary Fe-Cr system for lower temperatures using the Boltzmann-Matano method from chemical profiles of different samples. Another purpose with the project is to determine if the methods and the approach which are taken is viable and useful for calculating diffusion coefficients and if it can be used in studies to come. The simulations were in good agreement with other data at higher time intervals, but deviates at lower times. The calculated interdiffusion coefficients were in all cases lower than the expected values and as such the conclusion that is drawn is that the methods which are used could need further development. / Spinodalt sönderfall är ett fenomen som hindrar användningen av stål som innehåller ferrit under vissa förutsättningar. Med en större förståelse och mer kunskap om spinodalt sönderfall så kan nya ferritiska och duplexa rostfria stål utformas. Projektet är uppdelat i två delar, en experimentell del och en teoretisk del. Syftet med den teoretiska delen var att jämföra simulerade värden av amplituden och våglängden för spinodalt sönderfall, vilka erhölls från att lösa Cahn-Hilliard ekvationen med andra experimentella värden. Den experimentella delen utförs för att bestämma kemiska diffusionskoefficienter för Fe och Cr i det binära Fe-Cr system för lägre temperaturer med hjälp av Boltzmann-Matano metod från kemiska profiler av olika prover. Ett annat syfte med projektet är att ta reda på om de metoder och tillvägagångssätt som tas är livskraftiga och användbara för beräkning av diffusionskoefficienter och om den kan användas i studier framöver. Simuleringarna var i god överensstämmelse med annan experimentel data vid högre tidsintervall, men avviker vid lägre tider. De beräknade Interdiffusion koefficienterna var i samtliga fall lägre än de förväntade värdena och som sådan, dras slutsatsen att de metoder som används kan förbättras.

New materials are always being developed to get the best properties possible where needed. The way to create these materials and test them is also developing. When it comes to high-strength steels, a martensitic microstructure is a common choice. Martensite is a diffusionless phase transformation that generates the brittle martensitic microstructure. Tempering is a process where the brittle martensite is heat treated to make it more ductile and tough while simultaneously precipitating secondary phase particles that could help to strengthen the material. This study focuses on a novel dual-hardening martensitic steel that combines two different precipitates: carbides and intermetallics. The investigations are performed using simulations with the Thermo-Calc module TC-PRISMA to analyse the precipitation. The precipitation modelling is also compared to experimental data from the literature to evaluate the accuracy of the modelling. Out of the six alloys in this study, five were supposed to have NiAl precipitates. What was found was that two alloys, Alloy B and Alloy E, had NiAl precipitates that showed in PRISMA. In the three alloys that did not show NiAl precipitates, two of them did not have the phase stable at respective ageing temperatures. In the last alloy, that only had carbides, both of the precipitates showed up in PRISMA. More work needs to be done on co-precipitation, with comparison between simulations and experiments to confirm that the databases are reliable enough to be used to develop the materials of the future. / Nya material utvecklas hela tiden för att få de bästa möjliga egenskaperna där det behövs. Sättet att skapa dessa material, och testa dem, håller också på att utvecklas. När det gäller höghållfastastål är en martensitisk mikrostruktur ett vanligt val. Martensit är en diffusionsfri fasomvandling som genererar denna spröda martensitiska mikrostruktur. Härdning är en process där den spröda martensiten värmebehandlas för att göra den mer seg och duktil samtidigt som den skiljer ut sekundärfas-partiklar som kan hjälpa till att stärka materialet. Denna studie fokuserar på ett nytt dubbelhärdat martensitiskt stål som kombinerar två olika utskiljningar: karbider och intermetalliska utskiljningar. Undersökningarna utförs med hjälp av simuleringar med Thermo-Calc-modulen TC-PRISMA för att analysera utskiljningarna. Utskiljningsmodelleringen jämförs också med experimentella data från litteraturen för att utvärdera modellens noggrannhet. Av de sex legeringarna i denna studie skulle fem ha NiAl-utskiljningar. Det som konstaterade svar att endast två legeringar, legering B och legering E, hade NiAl-utskiljningar som visades i PRISMA. I de tre där det inte visades hade två av dem inte den fasen stabil vid respektiveåldringstemperaturer. Den sista legeringen hade bara karbider och i PRISMA dök de båda två upp. Mer arbete måste göras med samhärdning, med jämförelser mellan simuleringar och experiment för att bekräfta att databaserna är tillförlitliga nog för att kunna användas för att utveckla framtidens material.

In recent years, automated mineralogy has become an essential tool in geometallurgy. Automated mineralogical tools allow the acquisition of mineralogical and liberation data of ore particles in a sample. These particle data can then be used further for particle-based mineral processing simulation in the context of geometallurgy. However, most automated mineralogical tools currently in application are based on two-dimensional (2D) microscopy analysis, which are subject to stereological error when analyzing three-dimensional(3D) object such as ore particles. Recent advancements in X-ray microcomputed tomography (µCT) have indicated great potential of such system to be the next automated mineralogical tool. µCT's main advantage lies on its ability in monitoring 3D internal structure of the ore at resolutions down to few microns, eliminating stereological error obtained from 2D analysis. Aided with the continuous developments of computing capability of 3D data, it is only the question of time that µCT system becomes an interesting alternative in automated mineralogy system. This study aims to evaluate the potential of implementing µCT as an automated mineralogical tool in the context of geometallurgy. First, a brief introduction about the role of automated mineralogy in geometallurgy is presented. Then, the development of µCT system to become an automated mineralogical tool in the context of geometallurgy andprocess mineralogy is discussed (Paper 1). The discussion also reviews the available data analysis methods in extracting ore properties (size, mineralogy, texture) from the 3D µCT image (Paper 2). Based on the review, it was found that the main challenge inperforming µCT analysis of ore samples is the difficulties associated to the segmentation of the mineral phases in the dataset. This challenge is adressed through the implementation of machine learning techniques using Scanning Electron Microscope (SEM) data as a reference to differentiate the mineral phases in the µCT dataset (Paper 3).

One of the main sources of energy in this modern world is the gas turbine.  They reach extremely high working temperatures at peak capacity and hence require materials that can withstand the same.  Nickel-based superalloys have been widely used as working materials due to their various high-temperature properties, which help protect them from oxidation, corrosion,  and  creep.  This  high-temperature  strength  is  provided by the  gamma  prime (γ′)  phase  for  most  nickel-based  alloys.  This  study  deals  with understanding  the  effect of the mean γ′ phase size affected by different times and temperatures.  Different trial alloys have undergone different primary ageing cycles, followed by a subsequent secondary ageing  cycle.  Further,  the  mean  gamma  prime size  calculated  using  Image-Pro  coupled with  a  probability  density  function  for the mean  size  showed  significant  γ′  coarsening. Different temperatures and holding times also allowed for significant growth of secondary gamma prime structures.  These structures were found to impact the mean gamma prime size calculations significantly with their influence on the mechanical properties remaining unknown.  However, the mean gamma prime size remains similar to what was desired. / En av de viktigaste energikällorna i denna moderna värld är gasturbinen. De når extremt höga arbetstemperaturer vid toppkapacitet och kräver därför material som klarar av den höga temperaturen. Nickelbaserade superlegeringar har använts i stor utsträckning som material på grund av deras olika högtemperaturegenskaper, som hjälper till att skydda dem från oxidation, korrosion och krypning. Denna högtemperaturs hållfasthet uppnås från gamma prim-fasen (γ′) för de flesta nickelbaserade legeringar. Denna studie handlarom att förstå effekten av den genomsnittliga γ′-fasstorleken som påverkas av olika tider och temperaturer. Olika legeringar har genomgått olika primära åldringscykler, följt av en sekundär åldringscykel. Vidare visade den genomsnittliga gamma-prim storleken som beräknades med Image-Pro tillsammans med en sannolikhets densitetfunktion för medelstorleken av γ′ förgrovning. Olika temperaturer och hålltider möjliggjorde också betydande tillväxt av sekundära gamma-primstrukturer. Dessa strukturer visade sig påverka beräkningarna av den genomsnittliga gamma-primstorleken och egenskaperna av de mekaniska egenskaperna förblir okända. Den genomsnittliga gamma-primstorleken blir liknande det som var önskvärt.